Differential Case Assembly (Removal/Overhaul/Installation)
Note: This article has been revised in accordance with GM TSB#05-04-20-002, dated May 13, 2005.
REMOVAL PROCEDURE
1. Remove the rear axle shafts.
2. On vehicles with standard non-traction control rear axles, remove the sensor plug mounting bolt/screw from the wheel speed sensor.
3. On vehicles with standard non-traction control rear axles, remove the wheel speed sensor.
Carefully place the wheel speed sensor along the side of the rear axle housing.
4. Remove the differential carrier bearing cap bolts/screws.
IMPORTANT: Mark the differential carrier bearing caps R and L. This will ensure that they can be reassembled into their original positions.
Place the following components with the marked right and left differential bearings caps:
^ The right and left bearing outer races of the differential (side) bearings
^ The bearing shims
This will ensure that they can be reassembled into their original positions.
5. Remove the differential bearing shims.
NOTICE: Be careful when prying the differential case out of the axle housing to prevent damage of the cover gasket surface. Support the differential case during removal to prevent case from falling and being damaged.
IMPORTANT: Before removing the differential case from the rear axle housing, measure the differential ring gear-to-differential drive pinion gear backlash.
6. Remove the differential case from the rear axle housing.
DISASSEMBLY PROCEDURE
^ Tools Required
- J 22888-20 Differential Side Bearing Remover
- J 8107-2 Differential Side Bearing Remover Plug
1. Use the J 22888-20 and the J 8107-2 in order to remove the differential (side) bearing from the differential case. (if removing an Auburn type limited slip differential case, skip Step 2.
Note: When removing the side differential case bearings, you may discover that recommended tool J 22888-20A does not work because some limited-slip differential cases do not have notches for the jaws of the puller. Use tool J 34168 to press the bearing off the case.
2. Remove the following components from the differential case:
^ The upper and lower pinion gears
^ The pinion thrust washer
^ The left and right pinion gears
^ The differential side gear thrust washers
Mark the pinion gears and the differential case so the pinion gears may be reinstalled in the original positions.
3. Remove all of the ring gear bolts/screws from the differential case.
The differential ring gear bolts/screws are the left-hand thread type bolts/screws.
Discard the ring gear bolts/screws.
4. Use a brass drift and a hammer in order to drive the ring gear from the differential case.
Do not pry between the ring gear, the speed sensor reluctor wheel and the differential case if the ring gear tightly attached.
IMPORTANT: Replace the speed sensor reluctor wheel if the speed sensor reluctor wheel is removed from vehicles with standard rear axles.
5. Use a brass hammer in order to remove the speed sensor reluctor wheel (114).
6. Discard the speed sensor reluctor wheel.
ASSEMBLY PROCEDURE
^ Tools Required
- J 8092 Driver Handle
- J 21465-13 Driver Handle Extension
- J 25299 Differential Side Bearing Installer
1. Lubricate all of the components of the differential before assembly.
Use one of the following lubricants:
^ Axle lubricant
^ SAE 80W-90 GL-5 gear lubricant or an equivalent
2. Clean the connecting surfaces of the ring gear and the differential case.
Caution: Once the speed sensor reluctor wheel has been removed from the differential case, a new speed sensor reluctor wheel must be installed. The press fit may be lost if the speed sensor reluctor wheel is used more than once. This would allow the speed sensor reluctor wheel to rotate freely on the differential case causing a significant reduction in performance of the antilock brake system, which could result in bodily injury.
3. On vehicles with a non-traction control rear axle, place the speed sensor reluctor wheel over the differential case on the ring gear side.
Install the speed sensor reluctor wheel.
4. On vehicles with a non-traction control rear axle, position the ring gear over the speed sensor reluctor wheel.
Install the ring gear (2).
5. Install two ring gear bolts/screws into opposite sides of the ring gear.
(If converting to an Auburn type limited slip differential case, skip to Step 12.
6. Install the remaining new ring gear bolts/screws.
Finger tighten the new ring gear bolts/screws.
^ Tighten the differential ring gear bolts/screws alternately in progressive stages to 120 Nm (89 ft. lbs.).
NOTICE: Refer to Fastener Notice in Service Precautions.
7. Position the side gear thrust washers over the side gear hubs.
If the original side gear thrust washers are being installed, install the side gear thrust washers in their original positions.
8. Install the pinion gears into the differential case.
If the original pinion gears are being installed, install the pinion gears in their original positions.
9. Position one upper or lower pinion gear (without a pinion thrust washer) between the left pinion gear and the right pinion gear.
Rotate the pinion gears until one of the upper or lower pinion gears is opposite the loading opening in the differential case.
10. Position the other pinion gear between the left and the right pinion side gears so that the pinion gear shaft holes are aligned.
Rotate the pinion gears until the holes in the upper and the lower pinion gears are aligned with the holes in the differential case.
11. Rotate the upper and the lower pinion gears back toward the loading opening enough to permit sliding in the pinion thrust washers.
12. Use the J 8092, the J 21465-13 and the J 25299 in order to install the differential bearings (1) to the differential case.
INSTALLATION PROCEDURE
^ Tools Required
- J 25588 Side Bearing Shim Installer
1. Install the differential case into the rear axle housing.
IMPORTANT:
^ Do not reinstall the production bearing shims. The production bearing shims may break when tapped by a hammer.
^ Service bearing shims are reusable.
The differential bearings must have the original outer races in place when the bearings are reused.
^ Ensure that the bearing shim packs remain in each shim pack's proper position (right side or left side).
2. Use the following steps in order to install the differential bearing shims:
2.1. Select the correct left side bearing shim. The bearing shim must be 0.10 mm (0.004 inch) thicker than the shim that was removed from the left side.
2.2. Insert the left side bearing shim pack between the spacer and the left bearing race.
2.3. Loosely install the carrier bearing cap.
2.4. Select the correct right side bearing shim. The bearing shim must be 0.10 mm (0.004 inch) thicker than the shim that was removed from the right side.
2.5. Insert the bearing shim between the spacer and the right bearing race.
2.6. Use the J 25588 in order to drive the right bearing shim into position.
3. Install the differential bearing cap bolts/screws (5).
^ Tighten the differential carrier bearing cap bolts/screws to 75 Nm (55 ft. lbs.).
NOTICE: Refer to Fastener Notice in Service Precautions.
4. Measure the backlash.
Correct the backlash as necessary.
5. Install the rear axle shafts.
6. Install the following components:
^ The wheel speed sensor
^ The wheel speed sensor mounting bolt/screw
^ Tighten the wheel speed sensor mounting plug bolt/screw to 10 Nm (89 inch lbs.).